Absorbent paper product such as napkin or handkerchief, methods for manufacturing such a product, and apparatus implementing such methods

ABSTRACT

The invention relates to an absorbent paper product, such as a napkin or tissue, including at least two tissue paper plies which are superposed and joined, cut or precut into a desired format and connected to one another at least over a segment of a peripheral zone. The plies are joined along the segment by marking patterns without resort to glueing and at least one ply is fitted with embossing patterns in a central zone. The invention applies to sanitary and household papers, in particular disposable napkins and tissues.

RELATED APPLICATION

This application is a continuation of application Ser. No. 09/839,407,filed on Apr. 23, 2001, now U.S. Pat. No. 7,026,037.

FIELD OF THE INVENTION

The invention relates to an absorbent paper product for sanitary andhousehold uses. More specifically, it concerns products cut or precutinto such formats as paper handkerchiefs, hereafter tissues, disposabletable napkins, or similar products. These products include at least twosuperposed tissue paper plies which are joined to each other in anyknown manner.

BACKGROUND OF THE INVENTION

In the description below, the terms “marking” and “embossing” take thefollowing meanings.

“Marking” involves compressing some portions of a sheet includingseveral plies of tissue paper by forming compacted zones andsignificantly reducing the ply's thickness in these zones withouthowever forming corresponding salients on the opposite side. Whenseveral plies, in particular two plies, are “marked” jointly, they willbe combined and joined.

A marked product includes compressed zones of lesser thicknessconsisting of the marking patterns of the product.

“Embossing” involves creating one or several superposed tissue paperplies, salients on a first side with corresponding troughs on theopposite side of the plies, while increasing the thickness of the ply orsuperposed plies. The salients and troughs so made constitute embossingpatterns at the surface of the paper products. This technique as wellallows joining of the plies.

Most of the paper napkins presently on the market are connected byembossing at the edges, with entailed thickness in the joined peripheralzones.

Among the table napkins recently appearing on the market, some aremechanically joined at the edges of the plies and exclusively bymarking.

One of the marking procedures consists in moving two tissue paper pliesbetween an engraved steel cylinder and a smooth mating steel cylinder,the engraved cylinder has salients most of the time in the form of tipsat that portion of its surface corresponding to the napkin's edges. Thecompression applied by the cylinders suffices to join the plies. Theresultant cut product includes, on one of its surfaces, edges havingcompressed or compacted portions wherein the thickness is substantivelyreduced. There is no corresponding salient on the other product side.These products are characterized by the lack of excess thickness. Theircentral zone is flat, without excess thickness at its center. They lackbulk and “touch”, however, which are desired properties for productsused in wiping the skin.

Another marking technique to join the tissues' edges is described in thepatent application WO 95/27429 A.

This technique consists in marking each side of the product by using twoengraved cylinders each fitted with salient parts in the form of tips,the tips of one cylinder being configured tip-to-tip with the tips ofthe other cylinder. The two plies are therefore joined by marking and bythe point pressure applied by the cylinders. The two outer product sidesat these points are recessed inward the sheet at the points, each pointon one side matching another point on the other side.

This procedure entails very high accuracy and rigorous control.

The presently manufactured products incur the same drawbacks as thosedescribed above relating to conventional marking, namely that they areflat in the central zone.

European Patent Application 0 674 990 A describes embossed, paper tablenapkins. This embossing procedure allows creating, over a portion of thesurface of each ply constituting the product, salient patterns withcorresponding troughs on the opposite ply sides. As a result, theproduct is an embossed one and of greater thickness.

In this prior art of the above European Patent Application 0 674 990 A,there are three possibilities: embossing only the napkin's edges,embossing the full surface of the napkin, and embossing the edges withother embossing points selected in the central part between the edges.

In the first mode, once they are folded into four panes, the napkinsincur some asymmetry. When stacked and wrapped, the packs tend to warp.Moreover, the napkins' touch is unpleasant near the edges because of theasymmetric embossing salients.

In the second mode, it is difficult to implement the high compressionsrequired to emboss the full napkin surface, and consequently themechanical junction between the plies is degraded, while there is alsoloss of softness because of the full surface embossing.

The third mode is a compromise between the other two, resorting toselective distribution of the embossing points in the napkin's centralportion.

However, the drawbacks are a combination of those cited in the first andsecond modes.

The solution proposed in this prior art application EP 0 674 990 A tocircumvent these various drawbacks is a napkin with functional embossingcomprising an edge embossing and a decorative embossing pattern situatedat one of the folds opposite the edge embossing. An unembossed wipingsurface remains. In fact, the napkin portions that constitute the innerfolded edges are embossed in order that the product, once it has beenfolded, is of fairly constant thickness, thereby avoiding the warpingproblems of the stacked napkin packs.

Patent Application WO 94/12343 A discloses another joining technique atthe edges of a cut product, such as a tissue. This technique includesjunction by embossing and glueing, the ply junction being implemented byglueing the edges. However, the manufacture of such products isproblematic the moment an adhesive is used. Moreover, the adhesive willstiffen the product.

OBJECTIVES AND BRIEF DESCRIPTION OF THE INVENTION

The objective of the invention is palliation of the plurality of abovecited drawbacks by providing an absorbent paper product which is cut orprecut into a given format and which comprises at least two well joinedplies, the product being flexible, offering bulk and good touch in itscentral portion while also being pleasant to touch. The goal is toattain products of greater perceived thickness, as compared to mostconventional products, the latter being comparatively flat in theircentral zone. This perceived thickness in particular may result from thethickness differential between the peripheral napkin zone and itscentral zone.

Another objective of the invention is to provide simple methods tomanufacture the product of the invention and allow joining various kindsand types of patterns.

Another objective of the invention is to provide apparatus to implementthe methods of the invention.

As a remainder, the terms “marking” and “embossing” used in thefollowing description mean the following:

“Marking” involves compressing a certain portion of one or more tissuepaper plies by forming compacted zones and substantively reducing theply thickness in these zones without entailing corresponding salients onthe opposite side. When several, in particular two plies are markedjointly, they are joined and linked in the compacted, i.e. marked zones,and this is the case in the present invention.

A marked product includes compressed zones of lesser thicknessconstituting the product's marking patterns.

The invention also encompasses several marking methods, but excludesmarking combined with gluing.

The most conventional edge marking procedure consists in marking andconnecting at least two plies by moving these two plies between a hard,for example steel engraved cylinder of which the engraved patterns areof tips, and a smooth mating cylinder, also made of a hard, steel typematerial, and applying adequate compression.

Another procedure consists in marking a filigree-type pattern on anabsorbent paper product by stress-deforming the product which is made topass at least once between a hard and undeforming cylinder having linearengraved patterns and a mating cylinder of at least 40 Shore D hardness.

A product so marked offers the feature of glossy, smooth, marked andtranslucent surfaces forming filigrees, the unmarked surfaces beingmatte. Both the product and the method are described in detail in PatentApplication WO 97/20107 A.

“Embossing” involves creating salients on a first side with matchingtroughs on the opposite side of one or several superposed tissue paperplies by increasing the thickness of the ply or the superposed plies.The salients and troughs so made constitute embossings on the paperproducts' surfaces.

Various embossing modes are feasible. However the invention excludescombining embossing with glueing in the case of several plies beingembossed.

One of the embossing modes includes in moving one or several pliesbetween a hard engraved cylinder fitted with male engraving patterns anda hard engraved mating part fitted with corresponding female engravingpatterns.

In another procedure, one or more plies are made to move between a hard,for example steel, engraved cylinder fitted with male engraving patternsand a mating cylinder made of a deforming material, such as paper orrubber. The mating cylinder deforms to hug the male engraving patterns.The result so attained is close to that described in the aboveprocedure.

There are other embossing procedures which combine several hard andundeforming engraved cylinders with unengaged deforming cylinders. Inthis manner, several plies can be embossed and then joined.

Depending on the relative position of the engraved cylinders, thesalient portions of the embossing patterns of one ply may be positionedopposite the salient portions of the embossing patterns of another ply.Such mutual positioning is called “tip-to-tip”. They also may be offsetrelative to the salient portions of the embossing patterns of the otherply. This configuration is called “nested.” A hollow portion of a ply'sembossing pattern is then configured within a salient portion of theembossing pattern of the other ply.

Any kind of embossing is applicable in the present invention.

Preferably, the embossing mode used includes moving one or more pliesbetween an embossing, or engraved, hard, for example steel, cylinderfitted with engraved patterns and a mating cylinder, or smooth receivingcylinder, made of a deforming material, such as rubber.

In general, each ply is embossed separately and then the two embossedplies are superposed. However, the two plies also may be embossedjointly and be joined partly by the embossing.

In one embodiment of the invention described further below, ply markingmay be carried out on two superposed plies of which one already isembossed and comprises embossing patterns. In this case, the markingpatterns are partly or wholly identical with the embossing patterns.

One objective of the present invention is an absorbent paper productsuch as a napkin or tissue comprising at least two tissue papersuperposed plies which are joined, cut or precut into the desired formatand which are interconnected along at least part of a peripheral zone.

In an essential feature of the invention, the plies are linked along thepart by marking patterns, without glueing, and at least one ply isfitted with embossing patterns in the central zone.

In another feature of the invention, the two plies comprise identical ordifferent embossing patterns in the central zone.

In an advantageous feature of the invention, at least one of the pliescomprises only marking patterns in the peripheral zone.

In the peripheral zone of another advantageous feature of the invention,at least one of the plies is fitted with marking patterns partly orwholly identical with the embossing patterns.

In yet another feature of the invention, the marking patterns in theperipheral zone are filigrees.

In a preferred feature of the invention, the central zone of one ply isfitted with a decoration including a combination of embossed portionsand unembossed portions.

Another objective of the invention is a manufacturing method for theproduct of the invention, characterized in that it includes in

-   -   (a1) embossing a first tissue paper ply between a first engraved        cylinder and a second mating cylinder at least in the central        format zone,    -   (b) superposing a second ply and joining the two plies, along a        peripheral format zone, by marking between a first engraved or        unengraved cylinder in the zones corresponding to the peripheral        zone and a second hard, respectively unengraved and engraved        cylinder in the zones corresponding to the peripheral zone, in a        manner to join the plies to each other, and    -   (c) cutting or precutting into formats.

In another essential feature of the invention, the method comprises anadditional stage (a2) between the stages (a1) and (b), wherein thesecond ply is embossed between the second hard cylinder, which isengraved at least in a zone corresponding to the format central zone,and a second mating cylinder.

Another objective of the invention is a method characterized by:

-   -   (a1) simultaneously embossing first and second plies between a        first engraved cylinder, fitted with engraved zones        corresponding to the embossing patterns of the central format        zone and a first deforming mating cylinder fitted with deforming        unengraved surface zones or with engraved surface zones of steel        or the like which are positioned opposite the engraved zones of        the corresponding engraved first cylinder corresponding to the        embossing patterns of the format central zone,    -   (b) simultaneously with stage (a1), marking the first and second        plies between the first cylinder fitted with engraved and        unengraved zones corresponding to the marking patterns of the        peripheral zone and the first mating cylinder fitted with        unengraved or engraved surface zones respectively which are        situated opposite the respectively engraved and unengraved zones        of the first cylinder, and    -   (c) cutting or precutting into formats.

Another objective of the invention are apparatus implementing themethods of the invention.

In an essential feature of the invention, a first apparatus comprises:

-   -   a first set of cylinders comprising a hard, engraved cylinder        and a first deforming mating cylinder, the first engraved        cylinder being fitted with a first engraved zone corresponding        to the embossing patterns of the central format zone of the        first ply and of an engraving height h₁ and a second engraved        zone corresponding to the marking patterns of the format        peripheral zone and of an engraving height h₂, and    -   a second set of cylinders comprising a hard second cylinder and        a deforming second mating cylinder, the second engraved cylinder        being fitted with a first engraved zone corresponding to the        embossing patterns of the format central zone of the second ply        and of an engraving height h₃ and a second unengraved zone        corresponding to the peripheral format zone and of a height h₄,        the sum of the heights h₂ and h₄ being greater than the sum of        the heights h₁ and h₃.

In an essential feature of the invention, another apparatus comprises:

-   -   a first set of cylinders comprising a hard first engraved        cylinder and a deforming mating cylinder, the first engraved        cylinder being fitted with a first engraved zone corresponding        to the embossing patterns of the format central zone for the        first ply and being of an engraving height h₁ or h′₁ and a        second engraved zone corresponding to the marking patterns of        the peripheral format zone and of an engraving height h₂ or h′₂,        and    -   a second hard cylinder fitted with a first smooth zone        corresponding to the central format zone and of an engraving        height h₃ or h′₃ and a second plane zone corresponding in part        or in whole to the peripheral zone and of an engraving height h₄        or h′₄, the second zone being used for positioning itself        opposite the engraved zones of the first engraved cylinder        corresponding to the marking patterns, the sum of the heights h₂        or h′₂ and respectively h₄ or h′₄ being greater than the sum of        the heights h₁ or h′₁ and respectively h₃ or h′₃.

Another apparatus of the invention comprises the essential feature of:

-   -   a first set of cylinders comprising a hard engraved first        cylinder and a deforming first mating cylinder, the first        engraved cylinder being fitted with an engraved first zone        corresponding to the embossing patterns of the format central        zone for the first ply and being of an engraving height h″₁ and        a second smooth zone corresponding to the peripheral format zone        of an engraving height h″₂, h″₂ being less than h″₁,    -   a second hard engraved cylinder fitted with a first smooth zone        corresponding to the central format zone of an engraving height        h″₃ and a second engraved zone corresponding to the marking        patterns of the peripheral format zone and of an engraving        height h″₄₁ where h″₃ is less than h″₄ and the sum of the        heights h″₂ and h″₄ is greater than the sum of the heights h″₁        and h″₃.

In another essential feature of another apparatus of the invention, thelatter comprises:

-   -   a first hard engraved cylinder fitted with engraved zones        corresponding to the embossing patterns of the central format        zone and engraved or unengraved zones corresponding to the        marking pattern of the peripheral format zone, and    -   a first mating cylinder fitted with unengraved zones of        deforming material or engraved surfaces of hard material to        respectively being positioned opposite the engraved zones of the        first engraved cylinder corresponding to the embossing patterns        of the central format zone, and unengraved or engraved hard        surface zones to be positioned opposite the engraved or        unengraved zones of the first cylinder in the zones        corresponding to the marking patterns of the peripheral format        zone.

Other details and advantages of the invention are elucidated in thedescription below and in relation to the attached drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic topview of a product of the invention cut toformat size,

FIG. 2A is a schematic partial section along line II-II of the productof FIG. 1,

FIG. 2B is a variation of the product shown in FIG. 2A,

FIGS. 3, 4A-4G, 5A, 5B each represent a schematic and partial section ofother embodiments of the product of the invention,

FIG. 6 illustrates an implemention of a method of the invention andimplementing apparatus,

FIG. 6A shows a first engraved, hard cylinder of the apparatus of FIG.6,

FIG. 6B shows the deforming mating cylinder of the apparatus of FIG. 6,

FIG. 6C is an overall, schematic partial view of the hard, engravedfirst cylinder applied against the second hard engraved cylinder andillustrating the heights of the engraved zones,

FIG. 6D is a schematic partly cross-sectional view of the first engravedcylinder applied against the second, hard, smooth engraved cylinderalong line 6D-6D of FIG. 6,

FIG. 7 shows an alternative of the apparatus of FIG. 6,

FIG. 7A is a schematic and part cross-sectional view of the firstengraved cylinder applied against the second hard cylinder along line7A-7A of FIG. 7,

FIG. 8 shows another implementation of the method of the invention andthe corresponding apparatus to implement it,

FIG. 9 is an alternative of the apparatus of FIG. 8,

FIG. 9A is a schematic part cross-sectional view of the first engravedcylinder applied against the second hard cylinder along the line 9A-9Aof FIG. 9,

FIG. 10 shows another alternative of the apparatus shown in FIG. 8,

FIG. 10A is a schematic partial cross-section of the first engravedcylinder applied against the second engraved hard cylinder along line10A-10A of FIG. 10,

FIG. 11 illustrates another implementation of a method of the inventionand an implementing apparatus,

FIGS. 11A-11D are schematics of partial cross-sections of the firstengraved cylinder applied against the second engraved cylinder alongline 11A-11A of FIG.

FIG. 12 shows a variation of the apparatus shown in FIG. 11,

FIG. 13 shows an implementing variation of FIG. 11, wherein a third plyis used,

FIG. 14 shows still another way of implementing the method of theinvention and its implementing apparatus,

FIG. 14A shows the first engraved cylinder of the apparatus shown inFIG. 14, and

FIG. 15 shows a variation of the apparatus of FIG. 14.

DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS

The product of the invention is an absorbent paper product, inparticular made of tissue paper. It is cut into format size, for exampleinto a square or rectangle.

This product may be a tissue or a paper table napkin or any similarproduct.

This product comprises at least two superposed and joined tissue paperplies. The product described below and illustrated in FIGS. 1 through 5Bcomprises two tissue paper plies.

FIG. 1 is a schematic topview of a cut product 1, a table napkin or atissue, here shown square. It comprises a peripheral zone 2 subtending astrip of a given width l along the edges 3, 4, 5 and 6 of the product 1,and a central zone 7 enclosed by the peripheral zone 2.

The two plies are joined along peripheral zone 2 of width l by markingpatterns, without glueing. Depending on the particular marking techniqueused, the marking pattern may be constituted of simple or complexelements. It may be constituted of small surfaces in the form of disks,diamonds or others, which are implemented in a conventional manner. Italso may be in the form of lines, dashes, curves constituting a designand decoration when using the marking techniques implementing a filigreeas described in Patent Application WO 97/20107.

FIG. 1 shows a preferred product embodiment comprising an embossingpattern distributed over the full surface of the central zone in theform of small surfaces which, in this case, are represented by dots.Preferably, the central zone also comprises unembossed portions 8constituting decorations and creating softer zones as regards skincontact and products used in wiping the skin, such as napkins ortissues. In another preferred embodiment, the embossing patterns of thecentral zone constitute decorations alternating with unembossed zones.The unembossed zones are distributed across the square central formatzone so as to be symmetrical with the format medians. As a result, oncethe products is folded into four panes, it will offer some symmetry.

As regards the product of the invention, the plies are mechanicallyjoined in the peripheral zone and comprise a central zone which offersbulk and touch. The various product embodiment modes are shown in thecross-sections of FIGS. 2A, 2B, 3, 4A-4G, 5A and 5B.

The elements of each FIGURE bear the same reference numerals each timeincreased by 100.

As regards FIG. 2A, the peripheral zone 2 of width l is fitted withmarking patterns 9. The product thickness is less in the vicinity ofthese marking patterns. The first ply 10 points inward. The fibers ofthe first ply 10 were crushed, and the fibers of the second ply 11 werecrushed also but to a lesser degree, thereby assuring the junction ofthe two plies. In the central zone 7, the first ply 10 is embossed withembossing patterns 12 and thus the total product thickness is increasedin that zone. The most narrow parts 13 of the salients of the embossingpatterns point inward in order to limit the loss of softness in theseembossed zones.

FIG. 2B is a product variation over that shown in FIG. 2A wherein themarking patterns 109 of the peripheral zone 102 are near the level ofthe second ply 111 which is depressed inward. The first ply 110 isslightly depressed also. It is the first ply 110 which is fitted withthe embossing patterns 112 in the central zone 107.

In FIG. 3, the product having a peripheral zone 202 of width l is fittedwith patterns 214 which are simultaneously embossing and markingpatterns. The overall product thickness E₁ is greater in the peripheralzone than the thickness e₁ of the merely superposed two plies in theabsence of embossing and marking. In the trough 215 of the pattern 214,the ply 210 is depressed toward the product inside, the productthickness e in this trough which corresponds to the junction implementedby the marking of the two plies is reduced relative to the thickness e₁of the two plies when superposed in the absence both of marking andembossing. In FIG. 3, and in the peripheral zone 202, the markingpatterns are entirely identical with the embossing patterns. In another,implementation of the invention not shown, the marking patterns also mayonly be partly identical with the embossing patterns. In other words,the peripheral zone may be fitted with additional patterns that are onlyembossing patterns. The central zone 207 remains unchanged and solelycomprises embossing patterns 212.

FIG. 4A illustrates another embodiment of the product of the invention.The peripheral zone is fitted with marking and embossing patterns 314similar to those of FIG. 3. However, in the central zone, the two plieseach are fitted with embossing patterns. The ply 310 is fitted withembossing patterns 312 and the ply 311 is fitted with embossing patterns316. In FIG. 4A, the embossing patterns 312 and 316 are identical ineach ply. The troughs of the embossing patterns of one ply are in thetip-to-tip position with the troughs of the patterns of the other ply.The two plies in the central zone are perfectly symmetrical in theproduct's cross-section. In FIG. 4A, the overall product thickness E₂ inthe central zone is larger than the product thickness E₁ in theperipheral zone. In the case of FIG. 3, E₂ is substantially equal to E₁.

In FIG. 4B, contrary to the case of FIG. 4A, in the peripheral zone 402,it is the second ply 411 which is fitted with marking patterns identicalwith the embossing patterns 414, these marking patterns being impressedmainly on the second ply 411 and secondarily on the first ply 410.

In the central zone 407, the embossing patterns 412 and 416 of each ofthe plies 410 and 411 are identical with those denoted by 312 and 316 ofthe product shown in FIG. 4A.

In another implementation of the invention not shown, the embossingpatterns of the central zone also may be different in each ply which nolonger are symmetrical in cross-section.

The products shown in FIGS. 4C and 4D are different from the productsshown in FIGS. 4A and 4B by their peripheral zones 502 and 602 which arefitted with only a marking pattern 509 and 609, respectively, impressedmainly on the first ply 510 and secondarily on the second ply 511, andmainly on the second ply 611 and secondarily on the first ply 610. Inthese FIGURES, the two plies also are symmetrical in the cross-sectionof the central zone.

Also the two plies may be cross-sectionally asymmetrical in theircentral zone.

Such a product is shown in FIG. 4E. Illustratively, in the central zone707, the troughs of the embossing patterns 712 of the ply 710 may bepositioned or nested in the salient parts of the embossing patterns 716of the other ply 711.

As shown in FIG. 4E, the two plies may not make contact everywhere withone another over their deformed surface. Part 717 of the ply 710 doesnot make contact with part 718 of ply 711.

In this representation, and as regards the marking patterns 709 of theperipheral zone 702, it is the first ply 710 which is depressed first.FIG. 4F shows a variation wherein the second ply 811 is first topenetrate to the level of the marking patterns 809 of the peripheralzone 802.

FIG. 4G illustrates a product of the invention comprising three plies.Two embossed outer plies 850 and 851 and an unembossed central ply 852.In the central ply 857, the two plies 850 and 851 each compriseembossing patterns 862 in the tip-on-tip position. In the peripheralzone 872 of width l, the three plies 850, 851 and 852 are fitted withmarking patterns 879.

FIG. 5A illustrates a product wherein the peripheral zone 902 is fittedwith marking patterns such as those described for the product of FIG.2A. In this embodiment, the two plies 910 and 911 are fitted in theircentral zone with embossing patterns 919 and are joined by them. In FIG.5A, and in the peripheral zone, the ply 910 is fitted with the markingpatterns 909. Moreover, it is feasible also to mark the ply 921 as shownin FIG. 5B. The marking patterns 929 are present at the surface of theply 921.

The above described products may be fitted in their central zone notonly with embossing patterns but also with marking patterns formingfiligrees constituting other decorations.

The method of the invention offers the advantage that it provides aformatted product comprising a combination of marking and embossingpatterns, the peripheral zone being fitted at least with markingpatterns and the central zone at least with embossing patterns. Thisproduct comprises at least two plies, the marking and embossing patternsbeing situated on one ply or on different plies.

The illustrations below relate to implementing the method of theinvention. A particular method implementation will call for a particularimplementing apparatus.

FIG. 6 shows a first and simple implementation of the method of theinvention.

In the schematic shown in FIG. 6, the method includes a first stage toemboss a first tissue paper ply 10 between a first hard, engravedcylinder 1001 and a first mating cylinder 1002, in this instance made ofa deforming material such as rubber, in a manner to emboss the centralzone of the products of the invention at the level of the first ply. Ina second stage, a second tissue paper ply 11 is superposed on the firstembossed ply 10 and the two plies are marked jointly, in a way to bemutually joined, between the first hard engraved cylinder 1001 and asecond hard, smooth cylinder 1003 (that is an unengraved cylinder). Thefirst cylinder 1001 is engraved, for example, on surfaces correspondingto the peripheral zones 2 of the formatted products of the invention.Within the peripheral format zone, the two plies 10 and 11 are thensubjected to the compression required to join them. This compression isapplied by the system including the first engraved cylinder 1001 and thesecond hard smooth cylinder 1003. This principle will apply in allmethods of the invention described hereafter. At the exit of thismarking stage, the two plies are joined at least in the peripheral zone2. Next, the products are cut into their formats. A product made by thismethod is illustrated in FIG. 2A.

The apparatus implementing the above method is illustrated by the set ofthree cylinders shown in FIG. 6. The first engraved cylinder 1001 ismade of steel and its surface is fitted with engraved zones 1004 whichcorrespond to the embossing patterns 12 of the central zone 7 of theformatted products. The first engraved cylinder furthermore is fittedwith engraved zones 1005 situated between the engraved zones 1004 andcorresponding to the marking patterns 9 of the peripheral zone 2 of theformatted products.

In this FIGURE and all FIGURES in cross-section below, the engravedzones corresponding to the marking patterns are illustrated by thepresence of two dots (

)

The mating cylinder or receiving cylinder 1002 of the first engravedcylinder 1001 is made of a deforming material such as rubber andcomprises hollowed zones 1006 that will be positioned opposite theengraved zones 1005 of the first engraved cylinder 1001 corresponding tothe marking patterns 9 of the peripheral zone 2 of the formattedproducts. The second hard cylinder 1003 is made of steel or any otherundeforming material.

As regards FIG. 6A, the first hard, engraved cylinder 1001 is fittedwith two engraving levels, a first level for the engraving zones 1004corresponding to the embossing patterns 12 of the central zone 7 of theformatted products and a second level for the engraved zones 1005corresponding to the marking patterns 9 of the peripheral zone 2 of theformatted products. As shown in FIG. 6B, the first, deforming matingcylinder 1002, made for example of rubber, comprises recessed zones 1006that will be entered by the engraved marking zones 1005 of the firstengraved cylinder 1001 when the two cylinders are mutually compressedduring the embossing stage. Be it borne in mind that these engravedzones 1005 are not directly applied against the recessed zones 1006.

FIG. 6C illustrates the heights of the engraved zones of the firstengraved cylinder and of the second smooth and/or engraved hard cylinderof the apparatus of the invention.

The zone G corresponds to the surface of the cylinders which emboss thecentral zone of the formatted products and the zone M corresponds to thecylinder surface which marks the peripheral zone of the formattedproduct.

The engraved zones of the cylinders comprise projecting or salientportions. Illustratively, the engraving height h₁ of a salient portionis defined by the distance between the surface S of this salient portionand the central cylinder axis in a direction perpendicular to thesurface.

h₁ is the engraving height of the engraving zone of the first engravedcylinder corresponding to the embossing patterns of the central zone ofthe formatted products.

h₂ is the engraving height of the engraved zone of the first engravedcylinder corresponding to the marking patterns of the peripheral zone.

h₃ is the engraving height of the unengraved/engraved zone of the secondhard or engraved cylinder corresponding to the central zone of theformatted product.

h₄ is the engraving height of the unengraved or engraved zone of thesecond cylinder corresponding to the peripheral zone.

FIG. 6D illustrates the heights of the various engraved zones 1004 and1005 of the first engraved cylinder 1001 applied against the second hardcylinder 1003 of the apparatus shown in FIG. 6. The salient engravingparts are of height h₁ in the engraved zone 1004 corresponding to theembossing patterns 12 of the central zone 7 of the formatted products.In the engraved zone 1005 corresponding to the marking patterns 9 of theperipheral zone 2 of the formatted products, the salient engraving partsare of height h₂. The value of h₂ is greater than that of h₁. Theheights h₃ and h₄ are equal.

FIG. 7 illustrates a variation of the apparatus of FIG. 6. The productmade thereby is shown in FIG. 2A.

The method is identical to that described in relation to FIG. 6. Thedifference is in the second hard cylinder 1050 of the apparatus fittedwith recessed, smooth zones 1051 that receive the zones 1004 of theengraved first cylinder. The zones are not directly applied against eachother.

FIG. 7A illustrates the respective heights of the salient parts of thefirst engraved cylinder applied against the second hard cylinder of theapparatus of FIG. 7.

The first engraved cylinder 1001 in its engraved zones 1004 comprisessalient parts of a height h₁ and in its engraved zones 1005 comprisessalient parts of height h₂, where h₂ is greater than or equal to h₁. Thesecond steel cylinder 1050 comprises recessed zones 1051 producing asmooth recess of height h₃ and a smooth portion of height h₄ in the zoneof the cylinder 1050 that are positioned opposite the salient parts ofthe engraved zone 1005 of the first engraved cylinder 1001 correspondingto the marking patterns 9 of the peripheral zone 2 of the formattedproducts. The sum of the heights h₂ and h₄ is greater than the sum ofthe heights h₁ and h₃.

As regards FIG. 8, the method includes in embossing the first tissuepaper ply 210 between the first hard, engraved cylinder 1001 and thefirst deforming mating cylinder 2002. This first ply 210 is embossed inthe central zone 207 of the formatted product and also in the peripheralzone 202 of the formatted product. The second ply 211 then is foldedover the first embossed ply 210 and both plies are marked between thefirst hard engraved cylinder 1001 and the second hard smooth cylinder1003. In this marking stage, the two plies are marked along all or partof the embossing pattern of the first ply in the peripheral zone of theformatted product.

FIG. 3 shows a product manufactured by this method. It shows that, inthe peripheral zone 202 of the formatted product, the patterns 214 aresimultaneously embossing and marking patterns.

As regards the apparatus, the second hard cylinder 1003 is wholly smoothand the mating cylinder 2002 is deforming.

FIG. 6D shows the heights h₁ and h₂ of the salient parts of the engravedzones 1004 and 1005 of the first engraved cylinder 1001 applied againstthe second smooth hard cylinder 1003.

The apparatus shown in FIG. 9 is a variation of that of FIG. 8. Theapparatus of FIG. 9 differs by its second hard steel cylinder 4001 whichcomprises recessed zones 4006 that are positioned opposite the engravedzones 3004 of the first engraved cylinder 3001, corresponding to thecentral zone 207 of the formatted products.

The heights h′₁ and h′₂ of the salient parts of the engraved zones 3004and 3005 of the first engraved cylinder 3001 and the heights h′₃ and h′₄of the salient part of the second hard cylinder 4001 are shown in FIG.9A which, in a partial cross-section along the line 9A-9A of FIG. 9,represents the configuration of the first engraved cylinder 3001 and thesecond hard cylinder 4001 compressed against each other during themarking stage.

h′₂ is less than or equal to h′₁, h′₃ is less than h′₄, and the sum ofthe heights h′₂ and h′₄ is greater than the sum of the heights h′₁ andh′₃.

The product made by this apparatus is illustrative of the one shown inFIG. 3.

Contrary to the case of the apparatus of FIG. 8 and as shown in FIG. 10,the second hard cylinder 5001 can be engraved in the zones 5002corresponding to the marking patterns 109 of the peripheral zone 102 ofthe formatted products. The cylinder 5050 comprises recessed smoothzones 5055 that are positioned opposite engraved zones 5002 of thesecond engraved hard cylinder 5001. Between the engraved zones 5002, thecylinder 5001 comprises recessed zones 5056.

FIG. 10A shows the height of the zones' salient parts: h″₁ for theengraved zone 5057 and h″₂ for the plane zone 5055 of the first engravedcylinder 5050, h″₃ for the plane and smooth zone 5056 and h″₄ for theengraved zone 5002 of the second engraved hard cylinder 5001. h″₂ isless than h′″₁ and h″₃ is less than h″₄. The sum of the heights h″₂ andh″₄ is greater than the sum of the heights h′₁ and h″₃.

Accordingly, the function of the first engraved cylinder 5050 is toemboss and cooperate in marking with the second hard engraved cylinder5002 of which in turn the sole function is to mark.

The resultant product is shown in FIG. 2B. In the peripheral zone 102 ofthe formatted product, it is the second ply 111 which is compressed bythe cylinder 5001, and to a lesser degree the first superposed ply 110is too.

FIG. 11 illustrates another implementing method of the invention. Thismethod includes embossing, at least in a central zone 307 of theformatted products, the first tissue paper ply 310 between the firststeel engraved cylinder 1001 and the deforming smooth mating cylinder2002, in embossing, at least in the central zone 307 of the formattedproducts, the second ply 311 between the second hard engraved cylinder6000 and a second deforming mating cylinder 7000, and then superposingthe two separately embossed plies and marking them between the firstengraved cylinder 1001 and the second cylinder 6000, and lastly cuttingthe products into their formats.

The first engraved cylinder 1001 is similar to the cylinder shown inFIG. 6A and comprises two engraving levels. A first engraving levelcorresponds to the engraved zone 1004 used for the embossing patterns312 of the central zone 307 of the formatted products. The secondengraving level corresponds to the engraved zone 1005 used for themarking patterns 314 which in this instance are also the embossingpatterns of the peripheral zone of the formatted products.

The second engraved cylinder 6000 comprises engraved zones 6001 toemboss patterns of the central zone 307 of the second ply 311 andunengraved plane zones 6002 corresponding to the peripheral zone 302 ofthe formatted products.

The engravings of the zones 1004 and 6001 of the cylinder 1001 and 6000may be identical or different. The cylinders 1001 and 6000 must besynchronized in a way to allow superposing the two embossed plies intip-to-tip or in nested manner.

FIG. 4A shows a product made in the tip-to-tip manner. In thisimplementation, the product is made by embossing or engraved cylindersin the tip-to-tip position.

FIGS. 11A through 11D show various ways to distribute the engravingheights on two engraved cylinders of the apparatus of FIG. 11.

The first engraved cylinder 1001 comprises engraved zones 1004 of whichthe salient parts have a height h₁ corresponding to the embossingpatterns 312 of the central zone 307 of the formatted products for thefirst ply and comprises engraved zones 1005 of which the salient partshave a height h₂ corresponding to the embossing and marking patterns 314of the peripheral zone 302 of the formatted products.

The second engraved cylinder 6000 comprises engraved zones 6001 of whichthe salient parts have a height h₃ corresponding to the embossingpatterns 316 of the central zone 307 of the formatted products for thesecond ply 311 and smooth, unengraved zones 6002 having a height h₄ andcorresponding to the peripheral zone 302 of the formatted products.

In all possible implementations shown in FIGS. 11A through 11C, the sumof the heights h₂ and h₄ is greater than the sum of the heights h₁ andh₃.

As shown in FIG. 11A, when h₂ equals h₁, h₄ is greater than h₃ and whenh₂ is greater than h₁, h₄ is greater than or equal to h₃.

According to FIG. 11B, when h₂ is equal to h₁, h₄ is greater than h₃,and when h₂ is less than h₁, h₄ greater than or equal to h₃.

According to FIG. 11C, when h₂ is equal to h₁, h₄ is strictly less thanh₃ and when h₂ is strictly larger than h₁, h₄ is less than or equal toh₃.

FIG. 11D illustrates the nested position in the case of joining twoembossed plies using the engraved cylinders 1001 and 6000. Here h₂ isless than or equal to h₁, and h₄ is less than or equal to h₃. The sum ofthe heights h₂ and h₄ is greater than h₁ and greater than h₃.

By interchanging the cylinder 1001 and 6000 in FIG. 11, the productshown in FIG. 4B will be made.

As shown in FIG. 12, the first ply 510 is embossed in the central zoneof the formatted products between the first hard engraved cylinder 1001and the first deforming mating cylinder 1002. In parallel, the secondply 511 also is embossed between the second hard, engraved cylinder6000, and the second deforming mating cylinder 7000 is embossed also inthe central zone of the formatted products. The two plies 510 and 511then are superposed and marked in the peripheral zone 502 of theformatted products between the first engraved cylinder 1001 and thesecond engraved cylinder 6000. Lastly, the products are cut into theirformats.

The first engraved cylinder of the apparatus of FIG. 12 comprises theengraved zones 1004 corresponding to the embossing patterns 512 of thecentral zone 507 of the formatted products and further comprisesengraved zones 1005 corresponding to the marking patterns 509 of theperipheral zone 502 of the formatted products.

The deforming mating cylinder 1002 comprises recessed zones 1006 whichare positioned near the engraved zones 1005 of the first engravedcylinder 1001 corresponding to the marking patterns 509 of theperipheral zone 502 of the formatted products when the cylinders aremutually compressed.

Therefore, the first ply 510 is not embossed in the peripheral zone 502.

The second engraved cylinder 6000 comprises engraved zones 6001corresponding to the embossing patterns 512 of the central zone 507 ofthe formatted patterns, further unengraved zones 6002 corresponding tothe peripheral zone 502 of the formatted products. This smoothunengraved zones 6002 are positioned opposite the engraved zones 1005 ofthe first engraved cylinder 1001 which mark the peripheral zone 502 ofthe formatted products.

The second deforming mating cylinder 7000 also is fitted with recessedzones 7006 which are positioned near the unengraved smooth zones 6002 ofthe second engraved cylinder 6000 when the two cylinder are mutuallycompressed, whereby the second ply is also unembossed in the peripheralzone 502 of the formatted products.

The engraved cylinder 1001 may be such as shown in FIG. 6A and comprisestwo engraving levels. The mating cylinders 1002 and 7000 are the kindshown in FIG. 6B wherein deforming zones 1006 or 7006 are recessed.

FIGS. 11A through 11D illustrate the two engraved cylinders 1001 and6000 in their operational positions and show the distributions of thevarious heights h₁, h₂, h₃ and h₄ of the salient parts of the engravedzones.

Products made by means of such a method are shown in FIGS. 4C and 4E.

When the two engraved cylinders 1001 and 6000 are in the tip-to-tipposition, the resulting product is as shown in FIG. 4C. And when the twoengraved cylinders 1001 and 6000 are in the nested position, theresultant product is the one shown in FIG. 4E.

By interchanging the cylinders 1001 and 6000 in FIG. 12, the resultingproduct will be as shown in FIGS. 4D and 4F respectively correspondingto mutually compressed engraved cylinders 6000 and 1001 in thetip-to-tip and nested positions.

FIG. 13 shows a variation wherein a third smooth or embossed ply 852enters the marking stage between the two embossed plies 850 and 851. Thethird ply 852 also may enter the marking stage of the methods shown inFIGS. 11 and 12.

FIG. 4G shows the product resulting from the method illustrated in FIG.13.

Another objective of the invention is another method to simultaneouslycarry out the embossing and marking stages.

As shown in FIG. 14, this method includes simultaneously embossing thefirst and second plies 910 and 911 between the first engraved cylinder1001 and a mating cylinder 8000 at least in a central format zone 907,in simultaneously marking with the embossing stage, the first and secondplies 910 and 911 between the first engraved cylinder 1001 and thesecond mating cylinder 8000 fitted with smooth hard surfaces 8002 inzones which correspond to the marking patterns 909 of the peripheralzone 902 and in deforming zones 8003 corresponding to the engravedembossing zones 1004.

More specifically, and as shown in FIG. 14, the first and second plies910 and 911 are superposed and move between a hard steel engravedcylinder 1001 fitted with engraved zones 1004 corresponding to theembossing patterns 919 of the central zone 907 of the formatted productsand a mating cylinder 8000 fitted with deforming, unengraved surfacezones 8003, for example made of rubber, which are positioned oppositethe engraved zones 1004 of the first engraved cylinder 1001 when the twocylinders 1001 and 8000 are mutually compressed to implement the method.Accordingly, the two plies 910 and 911 are jointly embossed andconnected in the central zone 907 of the formatted products. In anotherimplementing method not shown, the smooth unengraved surfaces 8003 maybe replaced by hard and engraved zones.

The two plies are marked during the simultaneous motion between theengraved steel cylinder 1001 and the mating cylinder 8000. The engravedcylinder 1001 is fitted with engraved zones 1005 corresponding to theembossing patterns 909 of the peripheral zone 902 of the formattedproducts. The cylinder 8000 is fitted with unengraved smooth hard zones8006. The cylinder 1001 may be engraved at two levels in the manner ofthe engraved cylinder of FIG. 6A.

On the other hand, the mating cylinder 8000 shown in FIG. 14A is made ofsteel or any similar material. The mating cylinder comprises recessed orhollow zones that were filled by deforming inserts 8003, for examplemade of rubber, to assure that the smooth mating part is deforming inthe embossing stage.

The remaining surfaces 8006 of the mating cylinder 8000 are hard andsmooth and cooperate in marking.

The product so made is shown in FIG. 5A.

As regards the apparatus of FIG. 15, it is the mating cylinder 9000which is fitted with engraved zones 9005 corresponding to the markingpatterns 929 of the peripheral zone of the formatted product. Theengraved cylinder 6000 in turn is fitted with unengraved, hard zones6002 which are positioned opposite the engraved zones 9005 of thecylinder 9000 when the two cylinders are mutually compressed toimplement the method.

The cylinder 9000 furthermore is fitted with deforming inserts 9006 toprovide the smooth mating part in the embossing stage.

The resultant product is shown in FIG. 5B.

In general, all the above described steel cylinders of the apparatus ofthe invention also may be made of other materials offering similarhardnesses and properties. Again, the mating cylinders made of anydeforming material with the desired resiliency may be used.

As regards the engraved cylinders, mounted engraved plates also may beused for that portion of the engraved cylinders carrying out the centralzone embossing.

Again, the cylinders made of a hard material, whether smooth orengraved, may be fitted with tread strips at the cylinder ends to limitthe impacts caused by variations in pattern surfaces.

1. An absorbent paper product comprising at least two superposed pliescut or precut into a format with outermost edges and two zones, said twozones being a peripheral zone along said edges and adjacent to saidedges, and a central zone enclosed by said peripheral zone; wherein saidplies are joined together by marking patterns at compacted zones on oneside of said plies without corresponding salients on an opposite side ofsaid plies, without glue at least along a segment of said peripheralzone, and wherein at least one of said at least two superposed plies hasan embossing pattern in said central zone and wherein the at least twoplies have a thickness along said peripheral zone which is less than thethickness of said at least two plies in the central zone, and whereinsaid marking patterns are patterns constituted of simple or complexelements.
 2. Product as claimed in claim 1, wherein each of the at leasttwo plies has embossing patterns in the central zone thereof.
 3. Productas claimed in claim 2, wherein the embossing patterns in the centralzone are the same or different.
 4. Product as claimed in claim 1,wherein narrowest parts of the embossing patterns point inwardly betweensaid at least two plies.
 5. Product as claimed in claim 1, wherein atleast one of the at least two plies has marking patterns solely in theperipheral zone.
 6. Product as claimed in claim 1, wherein the centralzone includes filigree marking patterns.
 7. Product as claimed in claim1, wherein the at least two plies are joined to each other by embossingthe central zone of each ply.
 8. Product as claimed in claim 1, whereinthe central zone of one ply has a decoration including embossed andunembossed portions.
 9. Product as claimed in claim 5, wherein themarking patterns constitute filigrees.